Gantry-less wind turbine web installation with heating

ABSTRACT

A method of forming a wind turbine blade is provided which includes upper and lower blade mold halves, and a shear web having at least one aperture formed therein. A plurality of bulkheads are attached to the shear web and the shear web can be lifted and rotated, without need for a complex gantry/galactica apparatus, to be placed inside the lower blade mold. The upper mold half can then be closed with the shear web and bulkhead(s) disposed within the blade interior. A heating fluid can be pumped into the interior to pass through the bulkheads, circulating around the shear web and exiting the blade root with the assistance of a sump to pull the cold air outside the blade.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 USC 119 toProvisional application No. 62/748,830 filed Oct. 22, 2018, the entirecontents of which are hereby incorporated by reference.

BACKGROUND OF THE DISCLOSED SUBJECT MATTER Field of the DisclosedSubject Matter

The disclosed subject matter relates to a system, and correspondingmethod, of manufacturing large scale composite structures, e.g. windturbine blades. These large scale composite structures are typicallyformed from a two-piece mold and shear web insert which, once the bladehalves are molded, requires a complex mold installation and closureprocesses, including an overhead gantry apparatus for transporting andpositioning the shear web in order to complete fabrication.

Particularly, the present disclosure provides a system and correspondingmethod of shear web installation, without requiring a gantry to supportthe shear web, by employing support elements in the shear web whichserve as an installation guide while also ensuring stability of the webafter installation.

DESCRIPTION OF RELATED ART

Wind turbine blades generally comprise a hollow blade shell madeprimarily of composite materials, such as glass-fiber reinforcedplastic. The blade shell is typically made up of two half shells, alower pressure-side shell and an upper suction-side shell, which aremolded separately in respective female half molds, before being bondedtogether along flanges at the leading and trailing edges of the blade.This method of manufacturing a blade is illustrated schematically inFIG. 1 a.

Referring to FIG. 1a , this shows a mold 10 for a wind turbine bladedivided into two half molds, an upper suction-side mold 10 a and a lowerpressure-side mold 10 b, which are arranged side by side in an openconfiguration of the mold. A pressure side blade shell 12 a is supportedon a mold surface 14 a of the lower mold 10 a and a suction side bladeshell 12 b is supported on a mold surface 14 b of the upper mold 10 b.The shells 12 a, 12 b are each made up of a plurality of glass-fiberfabric layers, which are bonded together by cured resin.

After forming the shells 12 a, 12 b in the respective mold halves 10 a,10 b, shear web(s) 16 are bonded to an inner surface 17 of the windwardblade shell 12 a. Although two shear webs are depicted in FIGS. 1A-1C,the present disclosure includes the use of a single shear web. Indeed,single shear web embodiments can be less stable than dual web designs,thus the present disclosure has even greater utility for single webembodiments. As shown, the shear webs 16 are longitudinally-extendingstructures that bridge the two half shells 12 a, 12 b of the blade andserve to transfer shear loads from the blade to the wind turbine hub inuse. In cross-section, as shown in FIG. 1a , the shear webs 16 eachcomprise a web 18 having a lower edge 19 comprising a firstlongitudinally-extending mounting flange 20 and an upper edge 21comprising a second longitudinally-extending mounting flange 22.Adhesive such as epoxy is applied along these mounting flanges 22 inorder to bond the shear webs 16 to the respective half shells 12 a, 12b.

As shown in FIG. 1b , once the shear webs 16 have been bonded to theupper blade shell 12 a, adhesive is applied along the second (upper)mounting flanges 22 of the shear webs 16, and along the leading edge 24and trailing edge 26 of the blade shells 12 a, 12 b. The upper mold 10b, including the upper blade shell 12 b, is then lifted, turned andplaced on top of the lower blade mold 10 a in order to bond the twoblade half shells 12 a, 12 b together along the leading and trailingedges 24, 26 and to bond the shear webs 16 to an inner surface 28 of theupper blade shell 12 b. The step of placing one mold half on top of theother is referred to as closing the mold.

Referring now to FIG. 1C, a problem can arise when the mold 10 is closedwhereby the shear webs 16 may move slightly relative to the upper shell12 b. For example, the shear webs 16 may move slightly under their ownweight during mold closing or they may be dislodged by contact with theupper shell 12 b. The concave curvature of the upper shell 12 b also hasa tendency to force the shear webs 16 together slightly, as shown inFIG. 1C. Such movement of the shear webs 16 during mold closing mayresult in the shear webs 16 being bonded to the upper shell 12 b at asub-optimal position.

Additionally, conventional process to install a shear web in the molduse a complex installation fixture, e.g. overhead gantry. The large sizeand weight of the gantry fixture often creates complications withrespect to shop floor real estate, and operating the gantry fixturepresents a significant delay in manufacture cycle time.

Furthermore, there are various techniques which require employingpermanent fixtures to guide the shear webs during mold closure. Anexample of which is provided in U.S. Patent Publication No.2017/0151711, the contents of which are hereby incorporated in itsentirety, including the web guide structures. However, use of suchpermanent fixtures adversely impact the blade weight, as well asincreasing design complexity and costs, impacting the designed structureof the blade by becoming parasitic to blade structure in use. Moreover,the prior methods had to be part of the initial blade design.

There thus remains a need for an efficient and economic method andsystem for providing support for the webs/structure elements during theassembly phase of wind turbine devices that ensure proper placement ofthe shear web, without requiring a gantry fixture, and without impactingthe structure of the product.

In accordance with the present disclosure, a novel system is providedfor handling the shear web and establishing a gantry-less installationprocess.

SUMMARY OF THE DISCLOSED SUBJECT MATTER

The purpose and advantages of the disclosed subject matter will be setforth in and apparent from the description that follows, as well as willbe learned by practice of the disclosed subject matter. Additionaladvantages of the disclosed subject matter will be realized and attainedby the methods and systems particularly pointed out in the writtendescription and claims hereof, as well as from the appended drawings.

To achieve these and other advantages and in accordance with the purposeof the disclosed subject matter, as embodied and broadly described, thedisclosed subject matter includes a method of forming a wind turbineblade, comprising: providing a first blade half; providing a secondblade half; providing a shear web, the shear web including at least oneaperture formed therein; providing at least one bulkhead, the at leastone bulkhead attached to the shear web; placing the shear web and atleast one bulkhead on the first blade half; disposing the second bladehalf on the first blade half to define a blade interior therebetween,the shear web and at least one bulkhead disposed within the bladeinterior.

In some embodiments, a first bulkhead includes first and secondsymmetrical components, the first component disposed on first side ofthe shear web and the second bulkhead disposed on first side of theshear web. For example, the first and second symmetrical components canbe configured in a generally D-shape geometry.

In some embodiments, a second bulkhead includes first and secondasymmetrical components, the first component disposed on first side ofthe shear web and the second bulkhead disposed on first side of theshear web.

In some embodiments, the first component of the second bulkhead isconfigured in a generally D-shape geometry and the second component ofthe second bulkhead is configured with a tapered geometry.

In some embodiments, a first bulkhead is located proximate the root ofthe blade and a second bulkhead is located a predetermined distance fromthe first bulkhead.

In some embodiments, placing the shear web and bulkhead(s) on the firstblade half includes rotating the shear web from a horizontal to verticalorientation.

In some embodiments, the method also includes removing at least one lidfrom a bulkhead to expose the interior of the blade.

In some embodiments, the method also includes heating and/or cooling theinterior of the blade.

In accordance with another aspect of the disclosure, a method of forminga wind turbine blade is provided which comprises: providing a firstblade half; providing a second blade half; providing a shear web, theshear web including at least one aperture formed therein; providing atleast one bulkhead, the at least one bulkhead attached to the shear web;placing the shear web and at least one bulkhead on the first blade half;disposing the second blade half on the first blade half to define ablade interior therebetween, the shear web and at least one bulkheaddisposed within the blade interior; heating the interior of the blade,wherein heating includes directing fluid from the blade root through abulkhead towards the blade tip with the fluid circulating around theshear web.

In some embodiments, heating includes pumping fluid through an apertureon a first side of the shear web.

In some embodiments, heating includes suctioning fluid through anaperture on a second side of the shear web.

In some embodiments, heating includes directing fluid around the distalend of the shear web proximate the blade tip.

In some embodiments, heating includes directing fluid around the shearweb at a location between the root and tip.

In some embodiments, a first bulkhead includes a first aperture forfluid passage located therein, and a second bulkhead includes a secondaperture for fluid passage located therein, the first aperture offset ina chordwise direction from the second aperture.

In some embodiments the method also includes removing at least one lidfrom the second blade half to expose at least one bulkhead disposed inthe interior of the blade.

In some embodiments the method also includes performing a layupoperation after removal of the at least one lid.

In some embodiments, heating includes simultaneously pumping heatedfluid at the blade root and suctioning cold fluid at the blade root.

In some embodiments, heating includes routing conduits for distributingthe heated fluid through the bulkheads.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and are intended toprovide further explanation of the disclosed subject matter claimed.

The accompanying drawings, which are incorporated in and constitute partof this specification, are included to illustrate and provide a furtherunderstanding of the method and system of the disclosed subject matter.Together with the description, the drawings serve to explain theprinciples of the disclosed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of various aspects, features, and embodiments ofthe subject matter described herein is provided with reference to theaccompanying drawings, which are briefly described below. The drawingsare illustrative and are not necessarily drawn to scale, with somecomponents and features being exaggerated for clarity. The drawingsillustrate various aspects and features of the present subject matterand may illustrate one or more embodiment(s) or example(s) of thepresent subject matter in whole or in part.

FIGS. 1A-C depict cross-sectional views of a conventional wind turbineblade mold and manufacturing method.

FIGS. 2-4 are schematic representations of a bulkhead and shear webassembly.

FIG. 5 is a schematic representation of a shear web (Step 0), withattached support bulkheads (Step 1) and rotated (Step 2) forinstallation in a wind turbine blade mold, in accordance with anembodiment of the present disclosure.

FIG. 6 is schematic representation of a shear web disposed in an openmold half (Step 3), closed configuration (Step 4) and with the supportbulkheads removed (Step 5), in accordance with an embodiment of thepresent disclosure.

FIG. 7 is schematic representation of a shear web disposed in mold andattached to HVAC passages (Step 6), and with HVAC passages removed (Step7), in accordance with an embodiment of the present disclosure.

FIG. 8 is schematic representation of an exemplary air flow patternwithin the blade mold, in accordance with an embodiment of the presentdisclosure.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Reference will now be made in detail to exemplary embodiments of thedisclosed subject matter, an example of which is illustrated in theaccompanying drawings. The method and corresponding steps of thedisclosed subject matter will be described in conjunction with thedetailed description of the system.

The methods and systems presented herein may be used for large structureconstruction. The disclosed subject matter is particularly suited forconstruction of wind turbine blades. For purpose of explanation andillustration, and not limitation, an exemplary embodiment of the systemin accordance with the disclosed subject matter is shown in FIGS. 2-10and is designated generally by reference character 1000. Similarreference numerals (differentiated by the leading numeral) may beprovided among the various views and Figures presented herein to denotefunctionally corresponding, but not necessarily identical structures.

As shown in FIG. 2, the present disclosure includes a plurality ofbulkheads 200, 204 for use in connection with a shear web 100. Thebulkheads 200 include a removable lid 300 which can be detached from theframe of the bulkhead, to permit access to the interior of the blade.The frame 201 of the bulkheads can remain attached to the interiorsurface of the blade while the lids are removed, as shown. The bulkheadframe can be formed as a unitary piece (such as the generallysemi-circular unit as sown in FIG. 3), and/or as a multicomponentstructure that is assembled together to form a generally semi-circularunit (such as first half 201 a and second half 201 b as shown in FIG.3).

In some embodiments the union of the multi-component frames 201 a, 201 bis located offset from the portion of the frame that engages the shearweb 100, as shown. For example, frame subcomponent 201 a can be joinedto frame subcomponent 201 b at a location that coincides with a leadingand/or trailing edge of the blade. In some embodiments, the bulkheadscan be assembled with a combination of frame types (e.g. unitary frame201 on a first side of the shear web 100, and a multi-component frame201 a, 201 b on a second side of the shear web 100—as shown in FIG. 3).In some embodiments, the bulkhead can be formed from two frame sections201 that are joined at locations coinciding with the upper and lowerskin surfaces of the blade, as shown in FIG. 4. Frames, and anysubcomponents thereof, can include a male 202 and female 203 union, suchas a tongue and groove mating. Additionally, the frames 201 can be sizedwith an interior surface that is generally arcuate along the sides andgenerally planar along the tops and bottoms, as shown. The planartops/bottoms facilitates bonding with the planar surface of the shearweb 100. The lid 300 can be attached to the frame after the frame parts201 a, 201 b are assembled together.

In some embodiments, an adhesive (e.g. glue) is applied at the top andbottom edges of the shear web 100 for bonding with the bulkhead frames(i.e. the remainder of the shear web surface does not receive anyadhesive, such that the lids 300 can be removable). In some embodiments,the bulkheads 200 have generally D-shape, though alternative geometriesare included within the scope of this disclosure. Similarly, in someembodiments the bulkhead located between the shear web and thelower/pressure side of the blade is symmetrical with the bulkheadlocated between the shear web and the upper/suction side of the blade.Alternatively, in some embodiments the bulkhead located between theshear web and the lower/pressure side of the blade is asymmetrical withthe bulkhead located between the shear web and the upper/suction side ofthe blade, though alternative geometries are included within the scopeof this disclosure.

As shown in FIG. 5, shear web 100 is provided initially laid down on itsside in the horizontal position as shown in Step 0. Note, although thegeometry of the exemplary shear web 100 is shown having a taperedconfiguration from root 102 to tip 104, the present disclosure isequally applicable to shear webs of any shape/size. A plurality ofapertures 103 are formed in the shear web to permit fluid (e.g. air) topass through the cross section of the shear web. As the thickness of theblade tends to be greater proximate the root, there is a greater needfor heating to cure the additional materials. Accordingly, an embodimentof the present disclosure includes a greater number (e.g. two) ofapertures 103 formed in the web proximate the root 102 as compared tothe number (e.g. one) of apertures 103 formed in the web proximate thetip 104. These apertures accelerate heating/curing and reduce/eliminatestagnation of the flow of the heating fluid during a cure cycle. In theembodiment shown, two apertures 103 are formed in the root area whileadditional and apertures can be formed in the span wise direction. Insome instances the size and frequency of the apertures can vary with theshear web dimensions and location (e.g. more apertures, larger size,proximate the root with less apertures of smaller size proximate thetip). As previously noted, these apertures 103 serve as air passages inthe body of shear web to enable circulation of air in the root areawhere the thickness of infusion resin system and adhesive material aresignificant and to void stagnation of air flow in the tip area.

While the web is in horizontal orientation, supports or bulkheads 200are installed in the shear web 100, as shown in Step 1. In thisexemplary embodiment, the bulkheads 200 are attached to the shear web atspecific meter marks of the web span. In some embodiments the bulkheadsare positioned a fixed distance from each other, whereas in otherembodiments the spacing can vary along the blade span. In someembodiments the bulkheads are positioned proximate the root section,where the blade is heavier and taller (i.e. greater sized opening). Asshown, a first bulkhead 202 is positioned proximate the root of theblade and formed with two generally D-shaped members (as best shown inFIG. 2), one disposed on each side of the shear web 100. A secondbulkhead 204 is positioned distal of the first bulkhead 202 and formedwith one generally D-shaped member on a first side and a tapered shapemember on the second side (as best shown in FIG. 3). In the exemplaryembodiment shown, the taper can be asymmetrical with a top portion ofthe bulkhead 204 slanted downward at a greater angle than the bottomportion is slanted upward. Alternatively, the taper can be formedsymmetrically with upper and lower surfaces equally angled with respectto the central axis of the bulkhead. The degree of taper varies inaccordance with the contour of the blade such that the bulkhead shapecompliments the varying blade thickness and/or camber wherever thebulkhead(s) is positioned along the blade span. The bulkheads alsoinclude apertures or conduits 203 for receiving piping of fluid, e.g.air, circulation throughout the span of the blade, as described infurther detail below.

Although the exemplary embodiment depicts two bulkheads 202, 204disposed on the leading and trailing sides of the shear web 100,additional and non-uniform bulkheads can be attached to the shear web.For example, in some instances the size and frequency of the bulkheadscan vary with the shear web dimensions and location (e.g. morebulkheads, of larger size, proximate the root with less bulkheads ofsmaller size proximate the tip). The bulkheads proximate the root canextend a greater distance (or “height”) from the shear web 100 thanbulkheads proximate the tip. Accordingly, the bulkheads can beconfigured with a gradual reduction in height along the blade span tocoincide with the reduction in blade thickness and/or camber.

As described above, the bulkheads 200 can have a generally planar sideconfigured for engaging the shear web 100, and an opposing arcuate sideconfigured for engagement with the blade skin. In some embodiments eachbulkhead is configured as a multi-component structure with a firstbulkhead 202 a attached to a first side (e.g. leading edge side) of theshear web, and a second bulkhead 202 b attached to a second side (e.g.trailing edge side) of the shear web, as shown in FIG. 3. In suchmulti-component configurations, the bulkheads 202, 204 can be separatedby the shear web 100 such that there are no interconnecting partsbetween the bulkheads 202 a, 202 b and each bulkhead can beinstalled/removed/repositioned independent of the other. In someembodiments, the two bulkheads 202 a, 202 b can have an interlockingfeature that secures the two bulkheads together (with the shear web 100remaining therebetween).

The bulkheads 200 can be secured to the shear web with a variety ofattachment means including adhesive or mechanical union (e.g. screws,rivets, etc.) as well as frictional forces via interference fit. Oncethe bulkheads 200 are attached to the shear web 100, the shear web canbe lifted and rotated into a vertical orientation, as shown in Step 2.This operation can be performed with an overhead lift device, e.g.crane, and does not require the complex and cumbersome gantry apparatus(which extends along the length of the web). The shear web 100, withattached bulkheads 200, is then installed into the blade skin mold, asshown in Step 3 of FIG. 6, using the same overhead lift device employedfor Step 2.

As bulkheads 200 are precisely shaped to match the surface of the blade,the shear web 100 can be installed in its final position inside theblade mold by simply lowering and releasing the shear web 100 (withattached bulkheads 200) in the correct span wise location (Step 3). Thebulkheads 200 can serve as visual confirmation that the shear web 100 isproperly positioned. For example, markings (optical: laser projection,or physical lines) can be provided within the blade skin to coincidewith the edge of the bulkheads, when properly positioned.

Once positioned in the correct alignment, the second half of the mold isclosed on top of the first mold half (with the shear web 100 positionedinside), as shown in Step 4. Next, select portions, or lids 300, can beremoved from the bulkhead(s) to allow technicians to have access toblade's interior (Step 5) to permit subsequent manufacturing operations,e.g. hand layup of composite segments. In the exemplary embodimentshown, two lids 302, 304 are removable from the mold and are disposedproximate the root section. In the open, or removed configuration shownin Step 5, the shear web 100 is accessible as are the bulkhead frames202, 204. In the depiction of Step 5 in FIG. 6, the two segments of theupper blade surface are shown as removed from the remainder of the skinsurface for purpose of illustration only of the underlying bulkhead/webconfiguration; in operation, the surface of the blade remainscontiguous. In some embodiments, one or more bulkhead lids can beremoved from the blade and positioned outside the blade, with thebulkhead frames remaining attached inside the blade (as shown in Step5), to facilitate internal access.

Once the subsequent manufacturing operations, e.g. hand layup ofcomposite segments is finished, lids 300 are placed back on thebulkheads 200 and a heating system is attached to the fluid, e.g. air,passages that are built in to the lids, as shown in Step 6 of FIG. 7.Although the exemplary embodiment described focuses on air circulationfor heating of the turbine, the apparatus and method disclosed herein isequally applicable to cooling of the blade as well. After theheating/cooling operation (described in more detail below) is performedto the desired level of cure, the lids 300 can again be removed from thebulkheads 200 for completion of the blade and subsequent installation inthe field. The removability of the lids 300 is advantageous here in thatit reduces blade weight and any corresponding performance impact. Aspreviously noted, the bulkhead frames can remain permanently attached tothe interior blade surfaces. In accordance with another aspect of thedisclosure, a heating system and method that accelerates the cureprocess of the closed mold is provided, an exemplary schematic of whichis shown in FIG. 6. Attempting to provide a heating system by attachingto the root close-out and pumping heat inside the closed blade interiordoes not allow for effective penetration of hot air and stagnationhappens fairly close to the root of the blade.

As FIG. 8 shows, in the presently disclosed system, the interior of theblade is divided into two (e.g. root and tip) spaces using the bulkheads200 and their corresponding piping system. The bulkhead apertures 203and corresponding piping can be positioned and aimed such that theairflow does not directly impinge on the blade surfaces. Circulating thehot air in each of these cells separately improve the efficiency of theheating process. In some embodiments, a suction unit can be included onthe opposite side (lower side of FIG. 6) of the pumping system whichensures the smooth flow of air within both heating cells. Additionally,the location of pumping and suction units can be exchanged at the middleof the process in order to obtain a uniform degree of cure in both sideof the blade.

The hot air can be directed through the first bulkhead 202, through theapertures 103 in the shear web and back through the first bulkhead 202,so as to wrap around the shear web proximate the blade root. Thisestablishes a first circulation zone denoted by arrow “A” in FIG. 6.While traversing this path the air loses temperature via conduction andconvection to the neighboring components which expedites curing. Afterwrapping around the shear web the air is pulled toward the root via thecold suction apparatus again traversing through the first and secondbulkheads.

Additionally, the hot air can be directed, via conduits/piping 400through the first bulkhead 202 and dispensed at the second bulkhead 204,through the apertures 103 spaced along the remainder of the shear webspan, and back through the second bulkhead 204 where it can be againpiped/sucked through the first bulkhead 202. This establishes a secondcirculation zone denoted by arrow “B” in FIG. 6, which again wrapsaround the shear web along a greater distance of the blade span thancirculation zone “A”. This circulation zone “B” can include an airpassageway between the end of the shear web and the tip of the blade.

In some embodiments the heating/pumping operation is run independentlyof the cooling/suction operation. In some embodiments theheating/pumping operation is run simultaneously with the cooling/suctionoperation. Additionally or alternatively, both the heating/pumpingoperation and cooling/suction operation can be run on a continuous basisor on an intermittent basis with pre-programmed start/stop times and/orprocess milestones (e.g. detecting that the skin surface temperature hasreached a threshold value).

In accordance with an aspect of the disclosure, once the cure process iscompleted, the heating system as well as lids 300 can be removed fromthe blade. The blade can proceed (and be transported if necessary) to afinishing bay while the bulkhead frames (with no lids) remain attachedto it permanently. Additionally or alternatively, the bulkheads can beremoved, if so desired.

Accordingly, the system and method disclosed herein provide multipleadvantages including

-   -   1. Eliminates the demands/restraints on shop floor space due to        storing conventional large gantry fixtures for movement of the        shear web.    -   2. Accelerates web installation process and shortens the        production cycle time.    -   3. Avoids resource sharing and crane usage limitations as molds        in each production section share same fixtures.    -   4. Provides significant savings in capital expenditures for        launch of a new blade design (e.g. does not require sunk costs        associated with gantry fixture)    -   5. Accelerates the cure process and shortens the production        cycle time.    -   6. Bulkhead frames stay in the blade (very insignificant weight        and no impact on structural integrity of the blade structure)        needs approval from OEM's.    -   7. Avoids the need to create an air passage on the Shear Web.

Furthermore, the system and method disclosed herein provides a techniquefor stabilizing the web during installation; enables a one-step closureof the two mold halves such that the shear web can be bonded and curedsimultaneously to both mold skins; and ensures the correct position andorientation of the shear web such that there is no need for locatingfixtures nor a gantry system for supporting the web.

Although only a single shear web 100 is depicted in the exemplaryembodiment, additional shear webs can be employed within the scope ofthe present disclosure. Furthermore, although the shear web 100 isdepicted as an I-beam construction, alternative shear web configurationscan be employed, e.g. split beams having generally a U-shape or V-shapeconstruction, if so desired.

While the disclosed subject matter is described herein in terms ofcertain preferred embodiments, those skilled in the art will recognizethat various modifications and improvements may be made to the disclosedsubject matter without departing from the scope thereof. Moreover,although individual features of one embodiment of the disclosed subjectmatter may be discussed herein or shown in the drawings of the oneembodiment and not in other embodiments, it should be apparent thatindividual features of one embodiment may be combined with one or morefeatures of another embodiment or features from a plurality ofembodiments.

In addition to the specific embodiments claimed below, the disclosedsubject matter is also directed to other embodiments having any otherpossible combination of the dependent features claimed below and thosedisclosed above. As such, the particular features presented in thedependent claims and disclosed above can be combined with each other inother manners within the scope of the disclosed subject matter such thatthe disclosed subject matter should be recognized as also specificallydirected to other embodiments having any other possible combinations.Thus, the foregoing description of specific embodiments of the disclosedsubject matter has been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit thedisclosed subject matter to those embodiments disclosed.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the method and system of thedisclosed subject matter without departing from the spirit or scope ofthe disclosed subject matter. Thus, it is intended that the disclosedsubject matter include modifications and variations that are within thescope of the appended claims and their equivalents.

1. A method of forming a wind turbine blade, comprising: providing afirst blade half; providing a second blade half; providing a shear web,the shear web including at least one aperture formed therein; providingat least one bulkhead, the at least one bulkhead attached to the shearweb; placing the shear web and at least one bulkhead on the first bladehalf; disposing the second blade half on the first blade half to definea blade interior therebetween, the shear web and at least one bulkheaddisposed within the blade interior.
 2. The method of claim 1, wherein afirst bulkhead includes first and second asymmetrical components, thefirst component disposed on first side of the shear web and the secondbulkhead disposed on first side of the shear web.
 3. The method of claim2, wherein the first and second asymmetrical components are configuredin a D-shape geometry.
 4. The method of claim 1, wherein a bulkheadincludes a frame and a removable lid.
 5. The method of claim 4, whereinthe frame remains permanently attached to the shear web.
 6. The methodof claim 1, wherein a first bulkhead is located proximate the root ofthe blade and a second bulkhead is located a predetermined distance fromthe first bulkhead.
 7. The method of claim 1, wherein placing the shearweb and bulkhead(s) on the first blade half includes rotating the shearweb from a horizontal to vertical orientation.
 8. The method of claim 1,further comprising removing at least one lid from a bulkhead to exposethe interior of the blade.
 9. The method of claim 1, further comprisingheating the interior of the blade.
 10. The method of claim 1, furthercomprising cooling the interior of the blade.
 11. A method of forming awind turbine blade, comprising: providing a first blade half; providinga second blade half; providing a shear web, the shear web including atleast one aperture formed therein; providing at least one bulkhead, theat least one bulkhead attached to the shear web; placing the shear weband at least one bulkhead on the first blade half; disposing the secondblade half on the first blade half to define a blade interiortherebetween, the shear web and at least one bulkhead disposed withinthe blade interior; heating the interior of the blade, wherein heatingincludes directing fluid from the blade root through a bulkhead towardsthe blade tip with the fluid circulating around the shear web.
 12. Themethod of claim 11, wherein heating includes pumping fluid through anaperture on a first side of the shear web.
 13. The method of claim 11,wherein heating includes suctioning fluid through an aperture on asecond side of the shear web.
 14. The method of claim 11, whereinheating includes directing fluid around the distal end of the shear webproximate the blade tip.
 15. The method of claim 11, wherein heatingincludes directing fluid around the shear web at a location between theroot and tip.
 16. The method of claim 11, wherein a first bulkheadincludes a first aperture for fluid passage located therein, and asecond bulkhead includes a second aperture for fluid passage locatedtherein, the first aperture offset in a chordwise direction from thesecond aperture.
 17. The method of claim 11, further comprising removingat least one lid from a bulkhead to expose the interior of the blade.18. The method of claim 17, further comprising performing a layupoperation after removal of the at least one lid.
 19. The method of claim11, wherein heating includes simultaneously pumping heated fluid at theblade root and suctioning cold fluid at the blade root.
 20. The methodof claim 11, wherein heating includes routing conduits for distributingthe heated fluid through the bulkheads.